Collapsible container and method of making the same



Dec. 2,1947. F LA GRUA 2,431,697

COLLAPSIBLE CONTAINER AND METHOD OF MAKING THE SAME Filed June 29, 1944 5 Sheets-Sheet l INVENTOR. Tiuuif [a frraa ATTORNEY Dec. 2, 1947. F L RUA 2,431,697

COLLAPSIBLE CONTAINER AND METHOD OF MAKING THE SAME Filed June 29. 1944 s Sheefs-Sheet 2 INVENTOR.

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Dec. 2, 1947. 2,431,697

COLLAPSIBLE CONTAiNER AND METHOD OF MAKING THE SAME F. LA GRUA 3 Sheets-Sheet 5 Filed June 29. 1944 M INVENTOb flTTOR/VEY Patented Dec. 2, 1947 UNITED STATES PATENT OFFICE COLLAPSIBLE CONTAINER AND METHOD OF MAKING THE SAME Frank La Grua, Stonington, Conn. Application June 29, 1944, Serial No. 542,702

9 Claims.

This invention relates to the manufacture of collapsible containers made from cardboard, paperboard or other suitable material, capable of being folded flat to reduce the cost of transportation of the empty container from the container manufacturer to the user, for example, to manufacturers of food products, chemicals or similar merchandise.

The invention provides a method of making a collapsible container which is strong and rigid and will withstand the rough handling to which containers of this type are frequently subjected. The container consists of several parts which may be shipped flat to reduce the space required for shipment. The flat container may easily be opened up into cylindrical, oval, oblong or similar form, is then acted upon, as to fix its expanded form so as to resist collapsing or deformation and is then ready for filling with merchandise.

The container made according to my method has a foldable tubular wall provided with reinforcements along its upper and lower edges which after opening of the container into cylindrical form according to my method are inturned to render the container extremely rigid and capable of withstanding considerable abuse in shipment and handling.

The container may be produced at high production rates from continuous rolls of cardboard, paperboard, or other suitable ioldable material which in the process of manufacture is combined and reenforced with strips of edging of a material of greater strength and less deformability, under ordinary use than paperboard or cardboard, but capable of being formed into definite shape by the use of tools. Such edging may be made of soft carbon steel, aluminum or other metal or a plastic. The reenforced continuous band of board is then scored and cut into individual blanks, the ends of which are folded along two score lines and secured together to form flat tubular structures ready for shipment to the user at whose plant the collapsed blanks are expanded into cylinder form.

After expansion of the collapsed blank the reenforcing edging of the blank is turned in so as to form inwardly extending projections, The projections fix the form of the container, make the container walls resistant to deformation and serve as a ledge for supporting an end wall disk or closure.

After insertion of a bottom wall disk the container is ready for filling and closing with a suitable cover which may have the form of a flat disk or may be of the telescoping type having a 2 cylindrical rim or wall fitting over the top portion of the container.

The aims, objects, and advantages of the invention will appear more fully from the detailed description which follows accompanied by drawings showing for the purpose of illustration a manner in which the invention may be practiced.

The invention also consists in certain new and original features ofconstruction and combination of parts and steps hereinafter set forth and claimed.

Although the novel features which are believed to be characteristic of this invention will be particularly pointed out in claims appended hereto, the invention itself, its objects and advantages, and the manner in which it may be carried out may be better understood by referring to the following detailed description taken in connection with the accompanying drawings forming a part thereof in which:

Fig. 1 is a diagrammatic illustration of successive steps for forming a container according to this invention;

Fig. 2 is a side view of a fiat tubular container blank;

Fig. 3 is an end view of the blank shown in Fig. 2;

Fig. 4 is a side view of an expanded tubular container blank;

Fig. 5 is an end view of the blank shown in Fi 4;

Fig. 6 is a sectional side view through an expanded tubular container blank after the reenforcing or fixing operation;

Fig. 7 illustrates a manner in which edging may be attached to board by rivets formed from the edging;

Fig. 8 is a section taken on line 88 of Fig. 7 on an enlarged scale;

Fig. 9 illustrates a manner of to board by staples;

Fig. 10 is a section taken on on an enlarged scale;

Fig. 11 is a simplified of a stapling machine board;

Fig. 12 is a simplified diagrammatic illustration of a machine for scoring and cutting blanks from a continuous band of material;

Fig. 13 is a plan view of equipment for folding blanks into tubular form;

Fig. 14 is a sideview of the equipment shown in Fig. 15 is an elevationalview, partly in section, of a rim forming device;

attaching edging line iii-40 of Fig. 9

diagrammatic illustration for attaching edging to Fig. 16 is a plan view of a mandrel forming part of the rim forming device, the mandrel being shown in expanded condition; and

Fig. 17 is a plan view of the mandrel in contracted condition.

In the following description and in the claims various details will be identified by specific names for convenience. These namQ. .,..hOwever, are in tended to be as g enericein their, application; as the art will permit. Like reference characters refer to like parts in the several figures of the drawings.

In the accompanying drawlljlgs fgrming part of this specification certain specific disclosure... of the invention is made for the purpqse qif 3 planation, but it is understood that the'detai'ls may be modified in various respects; Without-de- 7;, parture from the broad aspect of the invention.

Fig. 1 illustrates diagrammatically a-series of Y steps by means ofwhich a cylindrical container may economically be aformed according'to my invention.

A continuous band -II of suitable foldable material, such as cardboard;paperboardand the likeyis unwound from a supply roll I2. -Rolls I3 and I4 contain continuous-ribbons or strips I5 andlfi offiat thin edging eapable of being'formed or bent into definite shape by appropriate-tools. Edging may suitably be made of soft carbon steel, aluminum or other metal; or of a plastic com position formable under pressure or pressure and heat. In the specific example illustrated the edging-consists of a thin metal band.- The board I I and the edging I 5 and- I-6 are continuously fed into suitable mechanism at station Afor attaching the edging I5 and I-B'to the side edge portions of the-board -I I so thattheouter edges-of the edging project over the outer edges-of the board. The edging may be attachedby bonding-with an adhesive compound or secured mechanically by '40 riveting, stapling, or a similarway. Machines for performing such attaching operations are available in the industry and do not per se form a part of this invention.

A continuous band consisting of board II and the attached edging I5 and I6 leaves the station A and is fed into a station IB containing scoring and cutting mechanism. The continuous band II, I5 and I6 is scored transversely at I'I and ;l8 and is cut into individual blanks I9.

The blanks I9 leaving station B are advanced to a station, .0 in a directionsubstantially at-right angles with respect to the direction of travel of the band II, I5 and I6.

At station C the blanks I 9 are folded along the score lines I 'I and I8 so that the ends of the blank including the edging I5 and I6 overlap. The overlapping portions of theiblank are-then secured together by adhesive or by mechanical means, such as staples, rivets, or the like, resulting in flat tubular blanks I9 which maybe staked and shipped in collapsed condition to the user of the container who will expand the tubular blanks into predetermined form as will be presv ently described.

The series of operations carriedout at stations A, B and C are. usuallyperformed at the plant of a box or container manufacturer and are collectively designated in Fig.1 by an arrow line I.

At the plant of the merchandise manufacturer, 70 the tubular collapsedblanks I9. are expanded into cylindrical form at a station D by Suitable equipment readily available in the industry:

The expanded cylindrical blank I'9 leaves station D for a further operation-at a station E 75 where a collapsible and expansible round mandrel 20 is inserted into the expanded blank I9. Expansible mandrels suitable for this purpose are available in the industry.

The tubular blank I9" and the mandrel 20 support the blank I9" during a succeeding forming operation performed at the edging. Blank I,9" and the mandrel Eli are advanced to a further-station. F at which the portions of the edging I5 and I 6 which extend beyond the edges of the board II are turned inwardly so as to form an inwardly projecting ledge or fiange fixing thegshaoe. of the expanded container blank. Preferably the strip I5 is inturned so as to form a reenforcingrim of L-shaped cross section and the strip I6 is inturned so as to assume J-shaped cross section; ,The: inwardly extending ledge formed by the rim I5 later serves as a support for a fiat disk forming the bottom of the container as will presently appear while the strip I5 forms a reenforcing top rim on the container.

After the rim forming operation the container blank I 9" and the mandrel 20 are advanced to a further station G at which the mandrel is collapsed to assume a reduced diameter for 'removal from the interior of the container.

The cylindrical blank I9' is finally advanced to a last station H at which an end wall disk 2| is inserted. The disk 2t rests upon the L-shaped flange formed on the bottom strip or rim I5.

The container I9', 2I is now ready to receive merchandise, and may be closed either by insertion of a fiat top disk or by means of a telescoping cylindrical cover which may be formed in the same manner as the container.

In Figs. 2 and 3 a collapsed tubular blank I9 is shown. The blank comprises a tubular side wall II of cardboard, paperboard, or other foldable material, and strips I 5 and I6 attached to the board at 2i so as to overlap the side edges 22 and 23 of the board by a margin a. The ends of the board II and of the strips I5 and I6 overlap by a margin b and form a seam portion 24, the ends of the board being secured together at 25.

Figs. 4 and 5 illustrate the blank I9 after expansion into cylindrical form prior to the rim forming operation.

Fig.- 6 shows the blank I9 after the rim forming operation. The top strip It has been turned inwardly so as to form a stiffening rim of substantially J-shaped cross section around the top edge of the container. wall. The bottom strip I5 has been inturned so as to form an inwardly projecting ledge or flange 25, the cross section of the metal rim resembling an L.

The fiat strips I5 and I B may be attached to the band I I of cardboard or paperboard in various well-known ways. 1

Figs. 7 and 3 illustrate a method of riveting in which rivets 21 are formed from a metal strip I6 itself by suitable punching tools, and are impressed into the board II as illustrated in enlarged cross section in Fig. 8.

Figs. 9 and 1() illustrate a manner of attaching edging It to board II by staples 28, an enlarged cross section being shown in Fig. 10.

A stapling machine for attaching strips to board is illustrated in simplified diagrammatic form in Fig. 11. The machine comprises a standard 29 integral with a base 39. A crank member BI is mounted on the standard 29 and operates a reciprocating plunger 32 mounted in guideways 33 on the standard. The plunger contains a supply of staples 28 Whichare impressed into the material passingbetween theplunger and the base. A stapling machine of the type illustrated in Fig. 11 may be used for performing the operations at station A.

A cutting and scoring machine is illustrated in simplified diagrammatic form in Fig. 12. The machine comprises a pair of cylinders 33 and 35 mounted on shafts 35 and 35. Cylinder 33 is provided with two scoring knives 3? cooperating with corresponding indentations in a corresponding cylinder 3d. The cylinder 33 further carries a cut-01f knife 38 cooperating with the corresponding depression 38 in the cooperating cylinder 35.

A continuous band of material consisting of board H and strips l5 and I5 is fed between the rollers 33 and 35. Two successive score lines ll and I8 are impressed in the band which is then separated into individual blanks by the cut-off knife 35 thus forming individual blanks, each blank comprising two transversely extending score lines. Mechanism for folding and seam scaling is diagrammatically shown in Figs. 13 and 1a.. The fiat blanks 55 are advanced along tracks 3%? and 40 in the direction of the arrow 5 i. As the blanks are advanced, the ends of the blank are acted upon by sweeps 42 and ts depressing the outermost portions of the blank and folding the blank along the score lines ll and i8.

During the first part of the folding operation, during which the ends of the blank are folded to a position substantially normal with respect to the center portion of the blank, the sweeps 52 and 43 pass from a position above the tracks 55 and 30 to a position on either side of the tracks. Thereafter the folding operation is completed and the end portions of the blank folded into a position substantially parallel with the center portion of the blank by the sweeps 42 and 53 passing underneath the tracks 39 and ill. During this final folding stage the ends of the container blank overlap as shown in Figs. 2 and 3 at it and are then secured together by a stapling machine diagrammatically shown at M. The blanks leaving the tracks 39 and ii] are readyfor shipment to the user.

A form of device for performing the rim forming operation is shown in Fig. 15. The cylindrical blank 1' is held on a. collapsible andexpansible mandrel so reenforcing and supporting the blank l9' against the forces exerted upon it during the rim forming operation.

The rim forming tools proper may be two sets of rollers 45 and 46 bearing down on the rims l5. and I6 respectively. Rollers 45 are adjustably mounted on a cross shaft Alon collars 48 provided with set screws 49 for adjustment-for any required diameter. The cross shaft ll is held on a vertical shaft 55 in a fitting 5|, the vertical shaft 50 being adjustable in a Vertical direction for movement towards the blank l9 during the rim forming operation. In the event plastic edging is employed, heat may be applied during the rim forming operation to render the edging more readily formable.

The second set of rollers 45 is mounted on stub shafts 52 adjustably mounted in bosses 53 on a base 54 clamped in place by set screws 55.

A central support 56 has a central bore 5? through which a shaft 58 extends having on its ends right and left screw threads 59 and Gil, respectively. The screw threads move pyramidal wedges 6| and 62 acting on inclined surfaces 63 of jaws 64 shown also in plan view in Figs. 16 and 17. The jaws, in turn, act on segments 65 having outside surfaces 66 corresponding in curvature to the inside surface of the blank 3'. The jaws 64 are held against rotation relatively to the central support 56 by fins 61 on the support 55 engaging notches 58 in the jaws. Springs 69 between the jaws tend to contract the elements of the mandrel against the action of the wedges 5i and 62.

In the operation of the device an expanded blank is placed on the collapsed mandrel whose elements have the relative position shown in Fig. 17. The mandrel is then expanded by turning the shaft 58 until it completely supports the wall of the blank.

The inturning or forming of the edging strips i5 and i5 is accomplished by a rotation of the rollers and 45 with regard to the mandrel carrying the blank, or vice versa. During the crimping the rollers 45 are advanced vertically towards the blank until the strips have been inturned or crimped to the desired degree. During the forming of the strip E6 the blank also moves slightly towards the central support 56, sufficient vertical clearance for this movement being provided between the fins 59 and the corresponding notches 68.

After the edge forming operation the mandrel 25 is contracted to the position shown in Fig. 17 to permit its removal through the inturned rims i5 and it. The crimped blank l9 is then ready for insertion of a fiat bottom disk 2i which is supported on the L-shaped rim I5 and completes the container body.

The inturning of the rims l5 and I6 considerably stiif ens the container against deformation in transport or in the course of its ordinary use.

The containers produced by my novel method are not only pleasing in appearance but extremely economical to manufacture and to set up. The machinery required at the several stations A to H is simple of construction and easy to operate.

The equipment for making collapsed blanks, stations A to C, is capable of continuous high speed operation, a particular feature being the use of rolls of material in distinction from the use of individual sheets.

The'setting up of containers ll, 2! from collapsed blanks may be done at the merchandise manufacturers plant with relatively simple equipment. One crimping or forming machine due to, its adjustability suffices for forming edging of blanks of a considerable range of diameters.

Obviously the present invention is not restricted to the particular example herein described and illustrated. Various modifications maybe made in the sequence of operations. For example cut and unscored blanks may be subse quently scored on a separate scoring machine.

Changes may also bemade in the specific blank structure. While I have shown and described a one ply blank in which edging is attached to one ply of board, it is obviously possible to laminate a second ply of board over the first, so as to place the edging between the two plies with only the portion of the edging extending beyond the outer edge of the blank showing. Instead of an overlap at the seam of the blank, the ends may be formed into a butt joint which may then be sealed with a strip of material. Other forms of machines may be substituted for the ones described without essentially changing my method of making, erecting or completing containers. All such changes, as well as additions, omissions, or a rearrangement in the order of operations manifestly do not constitute a departure from the spirit and teaching of this invention.

What is claimed is:

1. The method of forming containers which consists in providing a fiat collapsed tubular container wall of foldable board having attached to at least one end flat reenforcing edging extending beyond the edge of said Wall; expanding said collapsed wall to form a hollow structure; inturning said edging to form an inwardly extending stiffening ledge fixing the shape of the container; and inserting an end wall disk into said hollow structure so as to rest on said ledge.

2. The method of forming containers which consists in providing a continuous band of nonmetallic foldable material and a continuous strip of reenforcing edging; attaching said strip to said band so as to extend beyond one side edge of said band; scoring said band transversely of the band and cutting said band and attached strip into individual blanks, each blank comprising two score lines; folding each of said blanks along said score lines to form a flat tubular sleeve, the ends of each blank forming a seam portion; securing together the ends of the tubular sleeve at said seam portion; expanding said flat tubular sleeves to form hollow structures, in-turning said edging to form an inwardly extending stiflening ledge; and inserting an end wall disk into said hollow structure so as to rest on said ledge.

3. In the method of forming collapsible containers of cardboard, paperboard and the like the steps comprising, providing a continuous band of foldable board and a continuous strip of edging; attaching said strip to said band so as to extend beyond one side edge of said band; cutting and scoring said band transversely of said band to form individual blanks, each blank comprising two score lines; folding said blank along said score lines to form a flat tubular sleeve, the ends of said blank forming a seam portion; and securing together the ends of said tubular sleeve at said seam portion.

4. The method of forming a container which consists in providing a fiat collapsed tubular container wall of foldable board having attached to both ends strips of edging extending beyond the edge of said wall; expanding said collapsed wall to form a hollow structure; in-turning said edging to form inwardly extending flanges stiffening said wall and resisting collapsing of said wall; and inserting an end wall disk into said cylinder so as to rest on one of said flanges.

5. The method of forming containers which consists in providing a continuous band of nonmetallic foldable material and two continuous strips of edging; securing said strips to said band so as to extend beyond either side edge of said band; cutting and scoring said band transversely of the band to form individual blanks, each blank comprising two score lines; folding each of said blanks along said score lines to form a flat tubular sleeve, the ends of each blank forming seam portions; securing together the ends of said tubular sleeve at said seam portion; expanding said tubular sleeves to form hollow structures; in-turning strips of edging to form inwardly extending projections stiffening the expanded hollow structure; and inserting an end wall disk into said hollow structure so as to rest on one of said projections.

6. In the method of forming collapsible containers of cardboard, paperboard and the like, the steps comprising, providing a continuous band of foldable board, providing two continuous strips of edging; attaching said strips to the edge portion of said band so as to extend beyond the side edges of said band; cutting and scoring said band transversely of the band and the attached strips to form individual blanks, each blank comprising two score lines; folding said blanks along said score lines to form flat tubular sleeves, the ends of each blank lying in seam forming relation; and securing together the ends of said blank to form a seam.

7. The method of forming a container which consists in providing a flat collapsed tubular container wall of foldable board having attached to both ends strips of edging extending beyond the edge of said wall; expanding said collapsed wall to form a hollow structure; inturning one of said strips to form an inwardly extending flange substantially of L-shaped cross section and in-turning the other strip to form an inwardly extending ledge of substantially J-shaped cross section; and inserting a bottom end wall disk into said cylinder so as to rest on said L-shaped flange.

8. A collapsed fiat container blank comprising a substantially rectangular cardboard panel having two transverse score lines and two fiat bands of edging attached to the side edge portions of the panel so as to project beyond the side edges of the blank, the blank being folded upon itself along said score lines, the ends of the panel and bands being overlapped and secured together to form a tubular structure adapted to be expanded into cylindrical form.

9. In the method of forming a hollow container wall resistant to recollapsing from a collapsed flat tubular blank consisting of foldable board and having fiat edging attached to the end portions of the blank, the steps which comprise; expanding said blank to form a hollow structure; and in-turning a portion of said edging so as to lie in a plane at a substantial angle with respect to the remainder of said edging, the inturned portion forming a. stiffening rib on said edging resisting recollapse of said blank.

FRANK LA GRUA.

REFERENCES CITED The following references are of record in the 

